Ornamented wall board for outside weatherproofing



1 s. ODELL. 2,021,577

ORNAMENTED WALL BOARD FOR OUTSIDE WEATHERPROOFI'NG Nov. V19, 1935.

Filedvneo'. 31,. 2 sheets-sheet 1 nog),

Nov. 19, 1935.

L.. s. oDELL RNAMENTED WALL BOARD FOR OUTSIDE WEATHERPROOFING Patented Nov. 19, 1935 UNITED STATES PATENT oFF-ICE ORNAMENTED WALL BOARD FOR OUTSIDE I WEATHERPROOFINGrVv "Leslie s. odell, Montreal, Quebec, Canada, as-

signor to Building Products Limited, Montreal,

Quebec, Canada Application Deernber 31, 1931, Serial No. 584,109

' s claims. (oi. zo-f-sy v e tion lof a comparatively rigid wall board base This invention relates to the manufacture and use of paper or other brous wall board as an outside weatherproofing covering for the walls, roofs and other exposed surfaces of building structures. More particularly, the invention is concerned rwith eliminating certainfundesirable characteristics which have heretofore retarded the adoption and vsale of wall board forthis particular purpose in spiteof'its economy of: application and other advantages. j

When used for outsideweatherproofing work wall board is usually provided with -a weatherproofing surface of plain colored granular material and is nailed in place in sections with the edges of adjacent sections'butted togetherl One objection to the use of wall board in this relation isthat the` joints between the sectionsare extremely' conspicuous and must becovered by wooden or other battens in order to conceal their unsightly' appearance. Another objection Vis that the joints are deficient in weatherproong qualities and the material will not' remain in a perfectv-ly flat'conditionY onthe `nailing surface unless each section is'naile'd at both its upper andlowver'edges orcoveredv at these edges by wooden battens and both of these methods' increase the n cost of application and mar the vappeaiutnce'of' the finished surface. For these and other rea- .'sons the quantity'of wall board now sold for outside weatherproong purposes is relatively small Y in Ycomparison withthe'sale of competing coverings such as brickscolored ,siding-shingles; which are'inmuch greater demand on account of their superior "weatherproong qualities l and morel pleasingappearancewhen applied t'o'walls and "similar surfaces. f Y

"The present invention aims to provide'an ornamented Wall board covering for outside weatherproong purposes which compares favorably in appearance and weatherproong qualities with the now widely used brick colored shingles and which has 4the following additional` advantages: 1) Thel ornamental felt coverings4 of adjacent sections are joined together in edge vtoeclg'e relation to complete the continuity of the surface pattern. This reduces the quantity of felt required Yto cover a given section as Vcompared-with 'the'overlapping of adjacent felt sectionrequired in connection with the application of vsiding shingles. `It also provides ar better imitation of a brick, tilc'- orsto'ne surface'since thecontiguous 'sections-ol the pattern surface are .contained in a common flat plano and producesy a more realf between the nailing surface and the-ornamental felt covering? sections serves, in some manner, to eliminate the warping and Vrelative c displacement of the pattern sections which occurs, in the case of siding shingles, due to warping o1 the condition is provided wherein the compressible nature of the nailed down base material takes care of movement 'of the fastening nails due to warping in `such manner-as to prevent any displacement or distortion of the felt coverings. In

any event the mounting of the felt coverings on alignment of the pattern section which ordinarily occurs when 'feltsections carrying'the pattern are nailed directly tot the nailing surface. (3) Rapid assemblage of the ornamentedwall board sections vin their proper relation to complete the continuity of the granular surface pattern is facilitated by reason of the'factthat the1wall board jedges of eachapplied section servefas definite stops or abutments'facilitating proper placement of subsequently 'applied sections; f (4), The thickness'and comparative rigidity ofthe wall Yboard base to which the granular patternis applieden- -ables the use of tongueandggroovejoints at .the :upper and lower edges of contiguous vsections andV permits all of said' sectionsto be fastened: down in a perfectly flat condition byJ-.means of a rela- Jtively small number of nails which are passed only through the upper edge of each section,I the loweredge ofeach section being effectively held A'against displacementby its tongue -and groove connection with thena'iled down edgeof the next llower section and being arranged to overlie and entirely conceal the fastening nails. (5) The number of sections of wall board and the amount Y a wall board baseV prevents the bulgingor disa of nailing requiredato cover-.a given area of wall surface Vis considerably reduced as compared with the number of pieces and amount of nailingrequiredfor` covering the same surface area with siding` shingles, this being 'due to the*y fact that 5o f the-rigidity ofthe -ornamented wallboardl mate- Y rial permits it to. be conveniently handled and applied in large sections whereas,;in the casefof'Y siding shinglesthe -liexiblenature of theshingle 'strips is such that these rstrips ncannotbepconf `facev pattern.

veniently handled except in Ysmall sizes and the amount of nailing required for securing the flexible strips in place is considerably greater than that required where wall board is applied. Consequently, the cost of handling, `fitting into place and nailing the sections of wall board is considerably less than the similar costincident to the use of siding shingles and this, together with other advantages in favor of wall board coverings, more than oisets the slight diierence in the manufacturing cost of the two materials.

When the ornamented wall board sections are assembled in edge to edge relation on the surface to be covered the lines of the joints between the meeting edges of the sections are blendedV for at least a portion of their length with similarly extending lines of the granular surface pattern so that, at a relatively short distance from the covering, these joint lines are so confusedA with the lines of the pattern as to be substantially inconspicuous. This use lofthe granular surface pattern to obscure the joint lines of the sectional wall board covering constitutes a simple and eective method of eliminating the principal defect which hasheretofore retarded the sale and adoption of wall board for outside weatherproofing purposes.

Proceeding now to a more detailed description of the invention, referencewill be had to the accompanying drawings, wherein Y Fig. 1 is a view in front elevation of two complementary wall board sections constructed and ornamented in accordance. with this invention, said sections beingshown inv disassembled relation. Y

Fig. 2 is' a view similar to Fig. l but showing the complementary wall board sections in their assembled relation. Y v

Fig. 3 is a vertical sectional view along the line 3--3of Fig. 2. Y v v n Figure 4 is a view in front elevation of a section of wallboard having an ornamental surface pattern differing from that appearing in Figs. -l'to 3 inclusive. l Y

Figure 5 is a view similar to Fig. 4 but showing a further modification of the ornamental sur- Figure 6 is aview similar to Fig.2 but showing a greater number oiv sections in order to illustrate the` relative arrangement of the vertical end edges of contiguous sections. Y l

Each section of my improved .covering materiall includes a comparatively stiiT and rigid base .II comprising a body ot compressed paper, asbestos or other fibrous materials ordinarily employed inthe manufacture of products known to the trade as wall board or insulating board. The fibrous mass of the base may be of a homogeneous character or it may consist of a plurality of separate layers of paper or other brous material bonded together in .face Yto face relation by means of any of the cementing'agents usually employed in the wall board industry. The

. fibrous material, or thediierent layers of Vfibrous material, may also be rendered waterproof by treatment with any desirable .Waterproofing agents. When the base is complete it is provided on the weatherside with an adhesive layer I2 of asphalt or other watcrproong cementitious material of a bituminous nature. The, prepared surface I2 is then 'covered by a sheet I3 made of felt or other porous material saturated or irnprcgnated with a -waterproong compound such Vportion of the base as indicated at 24.

sheet I3 is completely covered with a weather resistant surface composed of 'ground stone, slate or other granular particles yIll embedded in asphalt. In the construction shown in Figs. l to 3 inclusive the weather resistant surface consists of diifer- 5 ently colored granular particles .applied in such a way as to present a plurality of Vrectangular brick colored areas I5 separated by intervening mortar colored areas I6 and provides a very .effective imitation of a brick surfacewhen the 10 sections of the material are assembled to complete the continuity of the pattern. In the construction shown in Fig. 4 the differently colored granular particles are applied .to present rectangular tile simulating areas I'I lseparated by l5 mortar colored areas I8. In the construction shown in Fig. 5, the differently colored granular particles are applied to present cut stone simulating areas I9 of rectangular contour separated by intervening mortar colored areas 20. 20

When a plurality of sections of the covering material are assembled on the nailing surface in edge to edge relation, as shown in Fig. 6, the lines of the joints formed between meeting edges of the sections are blended for at least a portion 26 of their length with similarly extending lines of the mortar colored portions of the granular surface pattern so that these joint lines are rendered substantially inconspicuous at a relatively short distance from the covering material. In the con- 30 v.covering sections it lwill be observed that the lines ofrthese joints are vblended throughout their length with similarly extending mortar colored l portions ofthe granular surface pattern and do 45 notbisect any of the brick colored areas.

As shown to advantage inFig. 3, the lower edge of each section is provided with a groove 22 lying Ybetween the inner and outer surfaces of the sectionY and adapted to receive a tongue 23 projecting 5o upwardly from the upper edge ofthe next lower section. The groove 22'is formed by cutting away the outer lower edge portion of the base II, the outerrwall of the groove being formed by the projecting portion I=3a of the felt strip I3 andwthe 55 inner wall vof the groovebeing formed bythe projecting portion IIa ofrthebase II.Y The tongue 23 at the upper edge lof each section is formed by cutting away the inner upper edge portion of the base Il of each section to provide a recessed 60 portion I Ib adapted to receive the projecting portion I Ia at the lower edge of the base of the next upper portion. The upper edge I3b of the felt strip I3 of each section is also cut away so that thisledge of the strip is `vbelowthe plane of the c5 horizontal shoulderformed by the bottom of the recess IIb. The purpose of spacing the upper edge of the felt strip below the shoulder formed by the'base of the recess IIb is to permit fastening nails to be driven through the intervening 70 It will also'be` noted that the nails 24 passing through the. upper portion of each section are concealed by the overlapping felt projection I3a of the next upper section. this felt projection Ilia being made 75 l areas.

i of the "mortar Ycolored strips of .the 4pattern 4and .will not Vappear 'in lprominent contrast with the projection l la is conned beneath the tongue 23 of the nailed down upper edge 'of the next lower section.Y The'base portion of each section which is exposed beyond the -edge |317 of the felt `covering strip is .preferably coated with asphalt or other waterproofing compound.

The improved covering material. described herein Amay be 'conveniently produced in the following manner: A wide ysheet of .felt .is l#impreg- .gnated with low melting point and then with high kmelting point asphalt or similar bituminous kwaterproofing compositions "in accordance with the practices usually followed inthe manufacture of lsiding shingles. One vside of the impregnated felt is then completely covered by Va foundation f layer of mortar colored vgranular particles deposited thereon 'from a suitable hopper lbeneath which the felt is passed after beingimpregnated with the asphalt or similar waterproofing substance. The granular side of the felt vis then partly covered by spaced rectangular patches of asphalt arranged to simulate parallel courses of brick, stone'or tile elements, said patches being conveniently applied by Yasphalt pick-'up wheels of suitable pattern Yhaving their lower portions moving in a bath `of asphalt and their upper portions disposed to contact with the granular` side of the web, the arrangement and use of such wheels being well knownjin connection with the manufacture lof brick simulating siding shingles.

,Asvlt leavesthe pick-up wheels the granular s'ide l of the felt passes beneath a second ,hopper containing granular particles of a different `color compared with the color of the previously applied particles. 'Ihe granular particles falling on .the asphalt patches applied `by the pick-up wheels are vembedded in the asphalt to form the brick, stone or tile elements of the pattern. Those par-` ticles from the second hopper which are deposited on the felt between the patches of asphalt f applied by the kpick-up wheelseventually fall; away from the felt or are removed so that the foundation layer of granular material is exposed between the brick, stone or tile areas in the form of narrow strips representing conventional mortar joints. Y

Following the application of the granular surface pattern the wide strip of Afelt is cut longitudinally and transversely into smaller sections of suitable length and width, each section being preferably wide enough to include several parallel -courses of the brick, stone orv tile simulating In practiceit has been found expedient to cut thefelt into sections having a length of approximately ten feet and a width of approximately one foot, these dimensions being suitable for rapid Vhandling `and application of the mate-V rial with a minimum amount of nailing. `When cutting the felt to provide these smaller sections the transverse rcuts are made along theV line of ythe mortar colored strips of the pattern in order to avoid, as far as possible, bisecting of the brick, stone or tile colored areas. ln other words these. cuts are madeso that the. lines of the vertical joints between the meeting edges of adjacentl sections of the felt willfollow, for at least. a portion of their length, the similarly extending lines adjacent brick, stone .or ythe simulating areas'of the pattern.r The longitudinal .cuts wthrough the felt strip are made so that they follow, throughr5 out their'entireL length, similarly extending mortar coloredstrips of ,the'patterm The transverseand longitudinal ycuts may bisect the co-'extensive mortar colored strips of the pattern or itheymay be 4ma'de close to the parallel edges of .the brick, stone or tilesixnulating areas.

Each smallsection ofthe feltis then attached to its wall board base Il by placing .it von the base and subjecting the assembly to pressure applied in any suitable manner. If the Abase en- 15 vgaging surface ofthe felt section is not sufliciently adhesive .it `may `'be coated, prior to the pressing operation, with .a ylayer of adhesive -asphalt or, alternately, a llayer of adhesive asphalt may be applied to the felt rengaging surface rof 'the base. zo 'The basel-I is, ofcourse, ycut to size and pro-V vided with the .groove 22 and the tongue 2l prior At`o the .application of the felt covering 'and' the latter arranged on the kbase so that its-edge l3b is spaced'inwardly from Vthe base of the tongue 23 25 with anlnner'horizontal recess adjacent its upper edge and an youter .horizontalrecess vadjitcent its lower edge, a sheet of waterproof material se- 35 cured to the outer Ysurface of said basewlth the upperedge of the sheet lying in a Yplane below the bottom wall of the `inner recess rand the lower' edge `of `the sheet projecting beyond the lower edge o'f the base, v4and a weather resistat surface 40 of rgranular'material covering the outer surface of said sheet.

2. Covering material composed of a plurality of` sections of siding materialconstructed as claimed in claim l and assembled in courses onthe sur- 45 face tobe covered, the projection provided' at the upper Vedge of the base of each section by the formation of theinner horizontal recess being p received in theouter recess at the lower edge of ythe ybase of the adjoining section in the'zlnext 50 upper course and theyprojection provided at the lower edge of the/.base of each section bythe .formation of the `outer recess being received in vthe inner horizontalrecess at thev upper edge of f 't the base of an adjoining section in Athe next lower 66 course, and the lowergedgeportion of the covering sheet of each section being butted against the upper edge of the covering sheet of the adjoiningV section in the next lower course.v l

3. Covering material of the character described'O comprising'a plurality of sections of siding material assembled in courses on the surface to be covered, each section .comprising a base' of substantial thickness and lstiffness formed'with an inner horizontal recess adjacent its upper Vedge 65 and an outer horizontal recess adjacent its lower edge,said'inner recess affording a projection at the upper edge of each vbase which is received in the outer horizontalrecess at the loweredge of the adjoining base in the next upper courseV and 70 the .said outer recess of each base affording a projection aty the lower edge v'thereof which is received in the inner Vrecess at the upper edge ofthe vadjoining base in the next lower course, and a sheet of waterproof material securedto the outer surface of each base with the upper 4edge of the sheet lying in a plane below the bottom wall of the inner base recess, and the lower edge of said sheet projecting beyond the lower edge of the base into abutting engagement wth'the upper edge of the covering sheet of the adjoining base in the next lower course, and joint concealing means on the outer surface of the sheets comprising a plurality of differently colored particles of granular material arranged to present pattern lines coinciding with and obsculring the jointlines formed By and between the meeting edges of s said sheets.

' LESLIE S. ODELL. 

